LEMON Manuals: Even more car manuals for everyone
Home >> Toyota >> 2008 >> FJ Cruiser RWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 209 (Manual Trans - C50) >> Input Shaft >> Disassembly

Input Shaft: Disassembly

WARNING: This page is about a different car, the 2008 Toyota Yaris. However, it is still accessible from the selected car via links, so may be relevant.
  1. INSPECT 4TH GEAR THRUST CLEARANCE 
    1. Using a feeler gauge, measure the 4th gear thrust clearance.

      Standard clearance: 

      0.1 to 0.55 mm (0.0039 to 0.0217 in.) 

      Maximum clearance: 

      0.55 mm (0.0217 in.) 

      If the clearance exceeds the maximum, replace transmission clutch hub No. 2, the 4th gear or input shaft rear radial ball bearing.

      Fig 1: Measuring 4th Gear Thrust Clearance Using Feeler Gauge
      G04831836Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  2. INSPECT 3RD GEAR THRUST CLEARANCE 
    1. Using a dial gauge, measure the 3rd gear thrust clearance.

      Standard clearance: 

      0.1 to 0.35 mm (0.0039 to 0.0138 in.) 

      Maximum clearance: 

      0.35 mm (0.0138 in.) 

      If the clearance exceeds the maximum, replace transmission clutch hub No. 2, the 3rd gear or input shaft.

      Fig 2: Measuring 3rd Gear Thrust Clearance Using Dial Gauge
      G04831837Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  3. INSPECT 4TH GEAR RADIAL CLEARANCE 
    1. Using a dial indicator, measure the 4th gear radial clearance between the gear and shaft.

      Standard clearance: 

      0.009 to 0.050 mm (0.0004 to 0.0020 in.) 

      Maximum clearance: 

      0.050 mm (0.0020 in.) 

      If the clearance exceeds the maximum, replace the 4th gear, 4th gear needle roller bearing or input shaft.

      Fig 3: Measuring 4th Gear Radial Clearance Between Gear & Shaft Using Dial Indicator
      G04831838Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  4. INSPECT 3RD GEAR RADIAL CLEARANCE 
    1. Using a dial gauge, measure the 3rd gear radial clearance between the gear and shaft.

      Standard clearance: 

      KOYO made bearing: 

      0.015 to 0.058 mm (0.0006 to 0.0023 in.) 

      NSK made bearing: 

      0.015 to 0.056 mm (0.0006 to 0.0022 in.) 

      Maximum clearance: 

      KOYO made: 

      0.058 mm (0.0023 in.) 

      NSK made: 

      0.056 mm (0.0022 in.) 

      If the clearance exceeds the maximum, replace the 3rd gear, 3rd gear needle roller bearing or input shaft.

      Fig 4: Measuring 3rd Gear Radial Clearance Between Gear & Shaft Using Dial Gauge
      G04831839Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  5. REMOVE 4TH GEAR 
    1. Using 2 screwdrivers and a hammer, remove the input shaft rear bearing shaft snap ring from the input shaft.

      HINT:

      Use a shop rag or piece of cloth to keep the snap ring from flying off.

      Fig 5: Identifying Screwdrivers, Hammer & Input Shaft Rear Bearing Shaft Snap Ring
      G04831840Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, remove the input shaft rear radial ball bearing and 4th gear from the input shaft.

      SST 09950-00020 

      HINT:

      • Do not tighten SST excessively.
      • Support the input shaft assembly by hand to prevent it from dropping off.
        Fig 6: Identifying SST, Press, Input Shaft Rear Radial Ball Bearing & 4th Gear
        G04831841Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  6. REMOVE 4TH GEAR NEEDLE ROLLER BEARING 
    1. Remove the 4th gear needle roller bearing and 4th gear bearing spacer from the input shaft.
      Fig 7: Identifying 4th Gear Needle Roller Bearing & 4th Gear Bearing Spacer
      G04831842Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  7. REMOVE 4TH GEAR SYNCHRONIZER RING 
    1. Remove synchronizer ring No. 2 from transmission clutch hub No. 2.
      Fig 8: Identifying Synchronizer Ring No. 2
      G04831843Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  8. REMOVE 3RD GEAR 
    1. Using 2 screwdrivers and a hammer, remove the clutch hub No. 2 setting shaft snap ring from the input shaft.

      HINT:

      Use a shop rag or piece of cloth to keep the snap ring from flying off.

      Fig 9: Removing Clutch Hub No. 2 Setting Shaft Snap Ring From Input Shaft
      G04831844Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
    2. Using SST and a press, remove transmission clutch hub No. 2 and the 3rd gear from the input shaft.

      SST 09950-00020 

      NOTE:
      • Do not tighten SST excessively.
      • Support the input shaft by hand to prevent it from dropping off.
        Fig 10: Identifying SST, Press, Transmission Clutch Hub No. 2 & 3rd Gear
        G04831845Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  9. REMOVE 3RD GEAR SYNCHRONIZER RING 
    1. Remove synchronizer ring No. 2 from the 3rd gear.
      Fig 11: Identifying Synchronizer Ring No. 2
      G04831846Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  10. REMOVE 3RD GEAR NEEDLE ROLLER BEARING 
    1. Remove the 3rd gear needle roller bearing from the input shaft.
      Fig 12: Identifying 3rd Gear Needle Roller Bearing
      G04831847Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
  11. REMOVE TRANSMISSION HUB SLEEVE NO.2 
    1. Remove transmission hub sleeve No. 2, the 3 shifting keys and 3 shifting key springs from transmission clutch hub No. 2.
      NOTE: Use a shop rag or piece of cloth to keep the shifting key and shifting key spring from flying off.
      Fig 13: Identifying Transmission Hub Sleeve No. 2
      G04831848Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
scientia non olet · About LEMON Manuals